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Introduction to the PureMash system, an alternative approach to controlling infections in an ethanol facility.

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  1. 1. Fuel Ethanol
  2. 2. What is PureMash? <ul><li>PureMash is a patent pending, generated chlorine dioxide based antimicrobial system to control competing microorganisms to yeast in fermentation processes. </li></ul>
  3. 3. Why Use PureMash Technology? <ul><li>High Organic Acids/Infections </li></ul><ul><li>Problem Systems not Addressable with Antibiotics </li></ul><ul><ul><li>Heat Exchangers </li></ul></ul><ul><ul><li>Cook Water </li></ul></ul><ul><li>Antibiotic Free Distillers Grain </li></ul><ul><li>High Standard Deviation with Current Practice </li></ul><ul><li>FDA Regulatory Compliance </li></ul>
  4. 4. PureMash – Target Markets <ul><li>Fuel Ethanol </li></ul><ul><ul><li>Dry Grind </li></ul></ul><ul><ul><li>Wet Mill </li></ul></ul><ul><li>Cellulosic </li></ul><ul><li>Sugar Based </li></ul><ul><li>Enzymes </li></ul><ul><li>Beverage </li></ul><ul><ul><li>Spirits </li></ul></ul><ul><ul><li>Beer </li></ul></ul><ul><ul><li>Wine </li></ul></ul><ul><li>Pharmaceutical </li></ul><ul><li>Food Processing </li></ul>
  5. 5. Regulatory
  6. 6. Regulatory Considerations Antimicrobials <ul><li>What antimicrobials will gain FDA approval? </li></ul><ul><li>Virginiamycin -Yes </li></ul><ul><li>Erythromycin – Not likely </li></ul><ul><li>Penicillin - Unknown </li></ul><ul><li>What will be the new antibiotic residual limits in distillers grains? </li></ul><ul><li>Therefore, what other antimicrobial technologies: </li></ul><ul><li>Effective </li></ul><ul><li>Economical </li></ul><ul><li>Meet FDA Requirements </li></ul>
  7. 7. Chlorine Dioxide – Where <ul><li>Utilized in approximately 30% of US drinking water supply </li></ul><ul><li>Promulgated by the EPA in 1999 </li></ul><ul><li>Poultry </li></ul><ul><li>Fruits & Vegetable Processing </li></ul>
  8. 8. EU Regulatory Compliant <ul><li>PUREMASH </li></ul><ul><li>Purate/MashGuard Chemistry </li></ul><ul><li>Registered under revised European BPD (Biocidal Product Directory) </li></ul><ul><li>Purate/MashGuard One registered under European (REACH) Program </li></ul>
  9. 9. Chemistry Fuel Ethanol Fermentation
  10. 10. What is Chlorine Dioxide? <ul><li>Chlorine Dioxide: </li></ul><ul><li>Must be generated on site </li></ul><ul><li>Resonance molecule </li></ul><ul><li>DISSOLVED GAS – Molecule does not dissociate in water </li></ul><ul><li>Maintains residual </li></ul><ul><li>Selective biocidal action </li></ul><ul><li>pH independent </li></ul><ul><li>Soluble in water </li></ul><ul><li>Does not react with ammonia </li></ul>Chemical Formula: ClO 2 Molecular Weight: 67.45 g/mole Melting Point ( o C): -59 Boiling Point ( o C): +11
  11. 11. PureMash Fermentation Technology: The Science <ul><li>Yeast tolerate and thrive when exposed to high concentrations of chlorine dioxide </li></ul><ul><li>Competing microbiology is reduced/eliminated while the Yeast continue to propagate </li></ul><ul><li>PureMash technology is selective – High efficacy at low concentrations allowing application to mash, propagator and fermentor </li></ul><ul><li>Byproduct is safe, regulatory free chloride ion – indeterminate from background </li></ul><ul><li>Increased ethanol efficiency – combining microbiology efficacy with the synergy of Yeast/chlorine dioxide </li></ul><ul><li>Applicable in ETOH processes where antibiotics cannot </li></ul>
  12. 12. Advantages of Chlorine Dioxide <ul><li>Broad spectrum Biocide and Virucide </li></ul><ul><li>Microbiological organisms do not become resistant or build tolerance </li></ul><ul><li>Synergy with the Yeast organism </li></ul><ul><li>Technology can respond “real time” to infections </li></ul><ul><li>No regulated or problematic byproducts </li></ul><ul><li>Technology can be applied to non-traditional infection sources, i.e. heat exchangers, mash, etc. </li></ul><ul><li>DDGS free of antibiotic residue </li></ul><ul><li>Multiple and simultaneous point application program </li></ul><ul><li>Process, systems DCS based control coupled with multipoint application assure a consistent treatment scheme </li></ul>
  13. 13. ClO 2 Efficacy & Chemical Selectivity <ul><li>ClO 2 reacts rapidly with sulfides </li></ul><ul><ul><li>amino acids containing sulfide groups </li></ul></ul><ul><ul><li>(cystine, thymine, etc.) </li></ul></ul><ul><ul><li>di-sulfide linkage(s) in protein synthesis </li></ul></ul><ul><ul><li>H 2 S from anaerobic bacteria (SRBs) </li></ul></ul><ul><li>Phenolic aminoacids (tyrosine) </li></ul><ul><li>ClO 2 can penetrate biofilm “in search” of these chemical functionalities </li></ul>
  14. 14. Application Engineering Fuel Ethanol Processes
  15. 15. Dry Grind Application Points <ul><li>Yeast Propagator </li></ul><ul><li>Interstage Mash Cooler (Pre/Post) </li></ul><ul><li>Cook Water </li></ul><ul><li>Yeast/Glucoamylase fermentor fill line </li></ul><ul><li>Fermentor </li></ul><ul><li>CIP </li></ul><ul><li>CO 2 Scrubber </li></ul>
  16. 17. Case Studies
  17. 18. Plant Scale Evaluations Two Plants <ul><li>Plant #1 </li></ul><ul><li>50 MGY </li></ul><ul><li>Dry Grind/Batch </li></ul><ul><li>Primary Motive – Antibiotic Free </li></ul><ul><li>Plant #2 </li></ul><ul><li>12 MGY </li></ul><ul><li>Dry Grind/Batch </li></ul><ul><li>Primary Motive - High Organic Acids – Unresponsive to conventional treatments </li></ul>
  18. 19. Plant #1 - Lactic & Acetic Acid Mean Lactic Acid .200 (w/w%) Mean Acetic Acid .056 (w/w%)
  19. 20. Plant #1 – Ethanol Yield Average EtOH 13.67 (w/w%)
  20. 21. Case Study – Plant #2 Metrics <ul><li>Plant experiencing high organic acids </li></ul><ul><li>Utilized various antibiotics, stabilized chlorine dioxide, hydrogen peroxide and cleaning with little success </li></ul><ul><li>Problem isolated in heat exchangers where antibiotics are not effective </li></ul><ul><li>Plant problem existed for over one year </li></ul><ul><li>PureMash directed to heat exchangers in addition to fermentors addressed the problem within 30 days </li></ul><ul><li>Period of Use – 9 Months </li></ul>
  21. 22. Interstage Cooler-Mash Treatment <ul><li>30 ppm ClO 2 </li></ul><ul><li>16 hour treatment </li></ul><ul><li>Untreated shows higher concentration of bacterial growth over time. </li></ul><ul><li>Treated shows lower concentration. </li></ul>Six Log Bacterial Reduction in Mash
  22. 23. Organic Acid – Plant #2 PureMash Treatment
  23. 24. Ethanol Yield- Plant #2 PureMash
  24. 25. Multi-Barrier Antimicrobial Technology
  25. 26. Multi-Barrier Antimicrobial Technology <ul><li>The combination of two antimicrobial technologies to gain : </li></ul><ul><li>Synergy </li></ul><ul><li>Increased Ethanol Production </li></ul><ul><li>Decreased Organic Acid </li></ul><ul><li>Regulatory Compliance </li></ul><ul><li>FDA Protocol </li></ul><ul><li>MCL (Maximum Contaminate Limit) </li></ul><ul><li>Common practice in drinking water and food processing industries </li></ul>
  26. 27. Multi-Barrier & Ethanol <ul><li>RBS has successfully evaluated chlorine dioxide in combination: </li></ul><ul><li>Virginiamycin </li></ul><ul><li>Erythromycin </li></ul><ul><li>Alpha/Beta Acid </li></ul><ul><li>Initial results indicate synergy via decreased organic acids </li></ul><ul><li>Reduced consumption both antimicrobials </li></ul><ul><li>Significant reductions when utilizing Virginiamycin </li></ul><ul><li>*RBS has applied for IP </li></ul>
  27. 28. Value Proposition-EtOH Gain
  28. 29. PureMash–Value Proposition <ul><li>Ethanol Efficiency </li></ul><ul><li>Lower Standard Deviation </li></ul><ul><li>Lower Organic Acids = Increased Production </li></ul><ul><li>Lower Glycerol </li></ul><ul><li>Address Infections in “real time” </li></ul><ul><li>Distillers Grains </li></ul><ul><li>Organic/Natural Beef Compliant </li></ul><ul><li>Increased Revenue by marketing AB free DG </li></ul><ul><li>Regulatory – EU has banned the use of antibiotics </li></ul><ul><li>FDA </li></ul><ul><li>Regulatory Compliance </li></ul><ul><li>Food Additive Petitions </li></ul><ul><li>MCL imposed in 2010 </li></ul>
  29. 30. Thank You